Power inverter

ABSTRACT

Water paths for feeding a coolant water through a power converter mounted on an automobile are arranged in parallel, openings are formed on the water paths respectively, heat radiating fins project from the openings, and the openings are closed by a base plate of the power module. Further, the base plate of the power module includes a metal in addition to copper to increase a hardness of the base plate, so that a deterioration of the flatness during fixing the fins with brazing is restrained.

BACKGROUND OF THE INVENTION

The present invention relates to an electric power inverter, forexample, a power inverter preferable for being mounted on a vehicle.

A typical electric automobile driven by an output power of a motorinstead of an internal combustion engine, and a hybrid-type electricautomobile driven by using together the internal combustion engine andthe motor exist. On such automobile, a rotary motor and a powerconverter for supplying electric power to the rotary motor are mounted.

The power converter has a function of converting a direct currentelectric power to an alternating current electric power to drive therotary motor, and may further have a function of converting thealternating current electric power generated by the rotary motor to thedirect current electric power to be supplied to a secondary battery. Forobtaining these functions, the power converter includes a semiconductormodule to form an inverter, a control circuit for controlling thesemiconductor and a capacitor.

A cooling of a semiconductor constituting an inverter is disclosed byJP-A-2005-259748.

BRIEF SUMMARY OF THE INVENTION

An object of the present invention is to provide a power converter inwhich a cooling efficiency is further improved.

A distinctive feature of the invention is that an opening is formed on acooling path for streaming a coolant and a heat radiating fin forcooling a semiconductor module projects from the opening into thecooling path so that the semiconductor module is cooled furtherefficiently and a cooling efficiency for a power converter is furtherimproved. The heat radiating fin is joined with the semiconductor by,for example, brazing.

Another distinctive feature of the invention is that the opening isformed on the cooling path for streaming the coolant and the heatradiating fin for cooling the semiconductor module projects from theopening into the cooling path and the opening is closed by a base plateonto which the heat radiating fin is fixed so that the semiconductormodule is cooled further efficiently and a cooling efficiency for apower converter is further improved.

The other distinctive feature is explained in embodiments.

The invention brings about an advantage of that the cooling efficiencyfor the semiconductor module is improved to provide the power converterin which the cooling efficiency is further improved.

In first and second embodiments as described below, the heat radiatingfin is mounted on the semiconductor module, and the heat radiating finprojects into a cooling water passage as the cooling path so that theheat radiating fin is cooled by the cooling water as the coolant to coolthe semiconductor module and the control circuit or smoothing capacitormodule for the semiconductor module, so that the power converter can becooled further efficiently.

In the first and second embodiments as described below, there is afurther effect of that a flatness of a heat radiating base plate as abase plate of the semiconductor module is kept accurately, and it isobtainable easily. Further, a plurality of insulating substrates eachincluding a plurality of semiconductor chips may be adhered in common tothe base plate so that a reliability in adhesion of the insulatingsubstrates is high and a heat radiating efficiency of the semiconductormodule is kept high.

In the below embodiments, the heat radiating fin is fixed to thesemiconductor module. The heat radiating fin is fixed to one of surfacesof the base plate of the semiconductor module by brazing. In the brazingprocess, the base plate needs to be heated to a high temperature. Whenthe base plate is made of a copper plate of superior thermalconductivity, pure copper has the superior thermal conductivity, butcauses a problem of that it is softened by being heated to the hightemperature in the brazing process to make the adhesion of theinsulating substrate with the semiconductor chip on its reverse surfacedifficult. If the copper forming the base plate includes impurity, itshardness is increased to solve the problem so that the flatness of thesurface to which surface the insulating substrate with the semiconductorchip is adhered is kept to make the process of adhering thesemiconductor chip to the base plate easy. On the other hand, a decreasein thermal conductivity causes a further problem. That is, antitheticdevelopments occur, and it is preferable for a content of the impurityto be adjusted.

These problems are not significant when the insulating substrate withthe semiconductor chip is small. An increase in voltage and electriccurrent supplied to the rotary motor mounted on the automobile causes anincrease in size of the insulating substrate of the semiconductormodule. Further, it is preferable for operability that the plurality ofthe semiconductor chips are adhered to the insulating substrate.Further, it is desired that the plurality of the insulating substratesare adhered in common to the metallic base plate. In this case, theinsulating substrate becomes great and an area of the base plate isenlarged to emphasize the above problem. In the embodiment 1 andembodiment 2 as described below, a relationship between the hardness andthermal conductivity of the base plate is clarified to solve theproblem.

Further, in the structure and producing process of the embodiments 1 and2 as described below, the semiconductor module is relatively easilymounted onto the heat radiating base plate, and the high reliability ismaintained during use in many years.

In the embodiments 1 and 2, an efficiency of thermal conduction betweenthe coolant and the semiconductor module is high, and the cooling isperformed with high reliability.

In the embodiments 1 and 2, a coolant for engine is usable as thecoolant so that it is further easily mounted on the vehicle to simplifya driving system. For using the coolant for engine, a structuralrelationship between the coolant water passage and the heat radiatingfin is improved in the above embodiments. Further, a connectingstructure between the cooling path and the smoothing capacitor isimproved.

In the first and second embodiments of the power converter forcontrolling two rotary motors, a structure of the whole of it is simple,and the high cooling efficiency is obtained. Further, such converter iseasily produced.

Other objects, features and advantages of the invention will becomeapparent from the following description of the embodiments of theinvention taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a system diagram showing an embodiment of electric motorcarincluding a power converter of the invention.

FIG. 2 is an exploded oblique projection view of the power converter ofthe invention.

FIG. 3 is an exploded oblique projection view of the power converter ofthe invention as seen in a direction different from a direction of FIG.2.

FIG. 4 is an exploded oblique projection view of the power converter ofthe invention as seen in a direction different from the directions ofFIGS. 2 and 3.

FIG. 5 is an oblique projection outer view of an embodiment of powerconverter of the invention.

FIG. 6 is an oblique projection outer view of the embodiment of powerconverter of the invention as seen from a front side surface.

FIG. 7 is a side view of the embodiment of power converter of theinvention as seen from a side at which a terminal box is attached.

FIG. 8 is a cross sectional view along I-I line in FIG. 5.

FIG. 9 is a view of the power converter of the invention with a housingin which a power module and a switch drive circuit substrate arearranged.

FIG. 10 is a view of the power converter of the invention with thehousing in which a capacitor module is arranged.

FIG. 11 is a view of the power converter of the invention with thehousing in which a rotary motor control circuit substrate is arranged.

FIG. 12 is a view of the power converter of the invention with thehousing from which a cover of a water path forming body is detached, asseen upward from a bottom side.

FIG. 13A is a front view showing the cover of the water path formingbody, and FIG. 13B is a side view of the cover.

FIG. 14 is a cross sectional view along II-II line in FIG. 12.

FIG. 15 is a cross sectional view along III-III line in FIG. 14.

FIG. 16 is a view of the power module of the invention from which aresin cover is detached.

FIG. 17 is a view of the power module of the invention as seen from thefin.

FIG. 18 is a cross sectional view along IV-IV line in FIG. 16.

FIG. 19 is a cross sectional view of another embodiment of the inventionof FIG. 18.

FIG. 20A is an outer plan view of the power module of the invention,FIG. 20B is a side view thereof, and FIG. 20C is a front view thereof.

FIG. 21 is an arrangement view of the power module of the invention.

FIG. 22 is a diagram of a circuit of the invention.

FIG. 23 is a cross sectional view showing the power converter of thesecond embodiment of the invention.

FIG. 24 is a plan view of an upper part of water path of the powerconverter of the second embodiment.

FIG. 25 is a side view of the power converter of the second embodiment.

FIG. 26 is a side view of the power converter of the second embodiment.

FIG. 27 is a side view of the power converter of the second embodiment.

FIG. 28 is an exploded oblique projection view of the power converter ofthe second embodiment.

DETAILED DESCRIPTION OF THE INVENTION First Embodiment <<ElectricAutomobile>>

FIG. 1 is a structural view showing an embodiment of a hybrid-typeelectric automobile including the power converter of the invention.Incidentally, the power converter 200 of the invention is applicable tothe pure electric automobile and the hybrid-type electric automobile,and the embodiment of the hybrid-type electric automobile is explainedbelow.

On the hybrid-type electric automobile 100, an engine 120, the firstrotary motor 130, the second rotary motor 140 and a battery 180 forsupplying a direct current of high voltage to the first rotary motor 130and the second rotary motor 140 are mounted. Further, a battery forsupplying a low voltage electric current (14V electric power) is mountedto supply the direct current electric power to a control circuitdescribed below, but it is not shown in the drawings.

A rotational torque by the engine 120, the first rotary motor 130 andthe second rotary motor 140 are transmitted to a transmission 150 and adifferential gear 160 to be transmitted to front wheels 110.

A transmission controller 154 for controlling the transmission 150, anengine controller 124 for controlling the engine 120, the rotary motorcontrol circuit on a rotary motor control circuit substrate 700 forcontrolling the power converter 200, a battery controller 184 forcontrolling a battery 180 of lithium ion battery or the like, and a maincontroller 170 are connected to each other by communication circuitlines 174.

The main controller 170 receives through the communication circuit lines174 information indicating conditions of the transmission controller154, the engine controller 124, the power converter 200 and the batterycontroller 184 as lower level controllers. On the basis of theinformation, the main controller 170 calculates controlling order foreach controller to be transferred to each controller through thecommunication circuit lines 174. For example, the battery controller 184reports to the main controller 170 electric discharge condition of thebattery 180 of lithium ion battery and condition of each of unit cellsconstituting the lithium ion battery as conditions of the battery 180.When the main controller 170 decides that an electric charge of thebattery 180 is necessary from the above report, the power converter isordered to generate an electrical energy. Further, the main controller170 manages output torques of the engine 120 and the first and secondrotary motors 130 and 140, and calculates a total amount of or a torquedistribution ratio among the output torques of the engine and the firstand second rotary motors 130 and 140, so that control orders based onthe calculation results are output to the transmission controller 154,the engine controller 124 and the power converter 200. The powercontroller 200 controls the first rotary motor 130 and the secondcontrol motor 140 on the basis of the torque order so that at least oneof the rotary motors is controlled to generate the ordered torque outputor the electric power.

The power converter 200 controls switching operation of a powersemiconductor forming the inverter to operate the first rotary motor 130and the second power converter 140 on the basis of the order from themain controller 170. By the switching operation of the powersemiconductor, the first rotary motor 130 and the second power converter140 are operated as motors or electric power generators.

When being operated as the motors, the direct current electric power isapplied from the high-voltage battery 180 to the inverter of the powerconverter 200 while the switching operation of the power semiconductorforming the inverter is controlled to convert the direct currentelectric power to a three-phase alternating current to be supplied tothe rotary motor 130 or 140. On the other hand, when being operated asthe electric power generators, a rotor of the rotary motor 130 or 140 isrotated by a rotational torque supplied from the outside to generate thethree-phase alternating current power on a stator of the rotary motorfrom the rotational torque. The generated three-phase alternatingcurrent power is converted by the power converter 200 to the directcurrent electric power to be supplied to the high voltage battery 180 sothat the battery 180 is electrically charged by the direct currentelectric power.

As shown in FIG. 1, the power converter 200 is constituted by acapacitor module 300 including a plurality of smoothing capacitors forrestraining a variation in voltage of the direct current electricsource, a power module 500 including a plurality of the powersemiconductors, a substrate (hereafter called as a switching drivecircuit substrate) 600 including a switching drive circuit forcontrolling the switching operation of the power module, and a substrate(hereafter, called as a rotary motor control circuit substrate) 700including a rotary motor control circuit for generating a PWM signal tocontrol a pulse width modulation as a signal for determining a width oftime period in the switching operation.

The high voltage battery 180 is the secondary battery of lithium ionbattery or nickel hydride battery to generate the direct currentelectric power of high voltage not less than 250-600 V.

<<General Construction of Power Converter>>

FIGS. 2, 3 and 4 are exploded oblique projection views of the powerconverter 200 to show schematically a general construction of the powerconverter 200. FIGS. 2, 3 and 4 are the exploded oblique projectionviews as seen in respective directions different from each other. FIGS.5, 6 and 7 are outline views of the power converters 200, and FIGS. 6, 7are the outlines views as seen in respective directions different fromthat of FIG. 5.

The power converter 200 has a housing 210 of box shape at a bottom whicha water passage forming body 220 including a coolant water path 216 as acooling path for circulating the coolant water is arranged. At thebottom of the housing 210, inlet pipe 212 and outlet pipe 214 forsupplying the coolant water to the coolant water path 216 project to anoutside of the housing 210. The water passage forming body 220 has afunction as a coolant path forming body forming the cooling passage, andan engine coolant is used as the coolant in this embodiment so that thestructure 220 has the function as the coolant water path forming body.

The power module 500 in FIG. 1 is constituted by first and second powermodules 502 and 504 juxtaposed with each other in the housing 210. Thefirst and second power modules 502 and 504 have respective heatradiating fins 506 and 507 for cooling. On the other hand, the waterpassage forming body 220 has openings 218 and 219. By fixing the firstand second power modules 502 and 504 onto the water passage forming body220, the heat radiating fins 506 and 507 for cooling project into thewater path 216 from the openings 218 and 219 respectively. The openings218 and 219 are closed by metallic walls around the heat radiating fins506 and 507 to prevent the coolant water from leaking from the openingsand to form the coolant water path.

The first and second power modules 502 and 504 are arranged atrespective sides to which a side wall surface of the housing 210 withthe coolant water inlet pipe 212 and the coolant water outlet pipe 214thereon is divided by an imaginary line perpendicular to the side wallsurface. The coolant water path formed in the water passage forming body220 extends from the coolant water inlet pipe 212 to another end along alongitudinal direction of the bottom of the housing, and is bent inU-shape at the another end to extend to the outlet pipe 214 along thelongitudinal direction of the bottom of the housing. The two set ofwater paths juxtaposed with each other along the longitudinal directionare formed in the water passage forming body 220, and the openings 218and 219 extending to the water paths respectively are formed in thewater passage forming body 220. The first power module 502 and thesecond power module 504 are fixed along the paths to the water passageforming body 220. The heat radiating fins projecting from the first andsecond power modules 502 and 504 into the water paths enable the coolingto be performed efficiently, and a close contact between the metallicwater passage forming body 220 and heat radiating surfaces of the firstand second power modules 502 and 504 brings about a structure forefficient heat radiation. Further, since the openings 218 and 219 areclosed by the heat radiating surfaces of the first and second powermodules 502 and 504, the structure is miniaturized and the coolingefficiency is improved.

First drive circuit substrate 602 and second drive circuit substrate 604are juxtaposed with each other on the first and second power modules 502and 504 overlaying them respectively. The first drive circuit substrate602 and second drive circuit substrate 604 form the switching drivecircuit substrate 600 shown in FIG. 1.

The first drive circuit substrate 602 arranged above the first powermodule 502 is slightly smaller than the first power module 502 as seenin a plane face. Similarly, the second drive circuit substrate 604arranged above the second power module 504 is slightly smaller than thesecond power module 504 as seen in the plane face.

The inlet pipe 212 and outlet pipe 214 for the coolant water arearranged on a side surface of the housing 210, and a hole 260 arearranged on the side surface to receive therein a connector 282 for thesignal. An inside of the housing 210 at which the connector 282 arearranged, a noise cut substrate 560 and a second electric dischargesubstrate 520 are fixed in the vicinity of the connector 282 for thesignal. These are mounted in such a manner that a surface on which thenoise cut substrate 560 and the second electric discharge substrate 520are mounted is parallel to a surface on which the first power module502, the second power module 504 and so forth are mounted.

A capacitor module 300 including a plurality of the smoothing capacitorsis arranged above the plurality of drive circuit substrates 602 and 604,and has a first capacitor module 302 and a second capacitor module 304each of which is arranged above the first drive circuit substrate 602and the second drive circuit substrate 604.

A holder plate 320 of flat plate shape is fixed closely to the innerwall surface of the housing 210 at a peripheral area of the holder plateabove the first capacitor module 302 and the second capacitor module304. The holder plate 320 supports the first capacitor module 302 andthe second capacitor module 304 on its surface adjacent to the powermodule and fixedly supports the rotary motor control circuit substrate700 on its reverse surface. The holder plate 320 is made of metallicmaterial to transmit a heat energy generated by the capacitor modules302 and 304 and the rotary motor control circuit substrate 700 to bedischarged to the housing 210.

As described above, the power module 500, switching drive circuitsubstrate 600, noise cut substrate 560, second electric dischargesubstrate 520, capacitor module 300, holder plate 320 and rotary motorcontrol circuit substrate 700 are contained by the housing 210, and anupper opening of the housing 210 is closed by a metallic cover 290.

Further, on the side wall as a front surface on which inlet pipe 212 andoutlet pipe 214 for the coolant water of the housing, a terminal box 800is mounted. The terminal box 800 has a direct current terminal 812 forsupplying the direct current electric power from the battery 180, aterminal bracket 810 for the direct current electric power, a terminal822 for alternating current electric power connected to the first rotarymotor 130 and the second rotary motor 140, and a terminal bracket 820for the alternating current.

The terminal bracket 810 for the direct current electric power iselectrically connected to electrodes of the first capacitor module 302and second capacitor module 304 through bus bars, and the terminalbracket 820 for the alternating current is electrically connected to theplurality of power modules 502 and 504 forming the power module 500through bus bars.

Incidentally, the terminal box 800 is formed by mounting on its body 840a bottom plate 844 on which the terminal bracket 810 for the directcurrent electric power is arranged and a cover 846. This is for makingan assembling the terminal box 800 easy.

The power converter 200 has a compact shape as shown in FIG. 5.

<<Each of Members of the Power Converter 200>>

The structure of the power converter 200 as shown in FIGS. 2-7 will beexplained in detail as follows.

(Housing 210)

In FIG. 8 as a cross section along line I-I in FIG. 5 and the abovedrawings, the housing 210 is made of a metallic material such asaluminum and has a substantially rectangular box shape. The housing 210has the water passage forming body 220 including the coolant water pathat its bottom, and an opening at its top. The coolant water path at thebottom of the housing 210 is folded back at an area opposite to theinlet and outlet ports so that two parts of the coolant water path arejuxtaposed with each other and the coolant water circulates in thecoolant water path. The folded back coolant water path has the waterpassage forming body 220 of dual structure between which a space forallowing the coolant water to flow is arranged at a central area.Openings 218 and 219 are formed along the water path at an upper plateof the water passage forming body 220 as shown in the drawings.

A pair of the first power module 502 and the second power module 504 isarranged at a lower region of the housing 210, and each of the firstpower module 502 and the second power module 504 is fixed above thewater passage forming body 220. The heat radiating surface of each ofthe first power module 502 and the second power module 504 includes theheat radiating fins 506 and 507 juxtaposed with each other. The heatradiating fins 506 and 507 project from the openings 218 and 219 intothe heat radiating fins 506 and 507. Further, the openings are closed bythe heat radiating surfaces of the power modules 502 and 504 around theheat radiating fins 506 and 507 to prevent the water leakage so that thesealed water path 216 is formed.

In this structure, the first power module 502 and the second powermodule 504 are cooled efficiently. Further, since the heat radiatingfins 506 and 507 of the first and second power modules 502 and 504 areinserted along the openings 218 and 219 respectively, the first andsecond power modules 502 and 504 are positioned with respect to thehousing.

The housing 210 has a relatively small hole 262 and a relatively greathole 264 of juxtaposed with each other (refer to FIG. 3). The terminalbox 800 is arranged on the side wall of the housing 210, the terminalbracket 810 for the direct current electric power I the terminal box 800is electrically connected to the first capacitor module 302 and thesecond capacitor module 304 in the housing 210 through the hole 262, andthe terminal bracket 820 for the alternating current in the terminal box800 is electrically connected to the first power module 502 and thesecond power module 504 in the housing 210 through the bus bars 860 and862. Parts of the bus bars are shown in FIG. 8.

<Power Module 500 and Stitching Drive Circuit Substrate 600>

FIG. 9 is a plan view showing the housing 210 in which the power module500 and the switching drive circuit substrate 600 are arranged.

The first and second power modules 502 and 504 constituting the powermodule 500 are arranged between the coolant water path and the rotarymotor control substrate 700 and first and second capacitor modules 302and 304 in the housing. The first and second power modules 502 and 504are juxtaposed with each other along the coolant water path.

The first power module 502 and the second power module 504 have thegeometrically identical structure in which respective direct currentterminals IT1 and IT2 and respective alternating current terminals OT1and OT2 are directed in a common direction, and the first power module502 and the second power module 504 are arranged symmetrically withrespect to a point so that the direct current terminals IT1 and IT2 faceto each other at a central position thereof, and the alternating currentterminals OT1 and OT2 are arranged to face to the side wall of thehousing 210. Since the first power module 502 and the second powermodule 504 are arranged to make the respective direct current terminalsIT1 close to each other and make the respective direct current terminalsIT2 close to each other, the first power module 502 and the second powermodule 504 are shifted with respect to each other along the longitudinaldirection.

Since the first power module 502 and the second power module 504 overlapthe switching drive circuit substrates 602 and 604 respectively as shownin FIG. 9, the direct current terminals IT1 and IT2 and the alternatingcurrent terminals OT1 and OT2 are visible on both narrower sides of theswitching drive circuit substrates 602 and 604.

The direct current terminals IT1 and IT2 of the first power module 502and the second power module 504 are electrically connected to theterminals of the capacitor modules 302 and 304 respectively, and thealternating current terminals OT1 and OT2 of the first power module 502and the second power module 504 are electrically connected to thealternating current terminal bracket 820 in the terminal box 800.

The alternating current terminal OT1 of the first power module 502 isconstituted by terminals OT1 u, OT1 v, OT1 w corresponding to respectiveU, V and W phases, and the terminals OT1 u, OT1 v, OT1 w extend alongone of the narrower sides of each of the power modules 502 and 504 tofurther be connected through the bus bars 860 u, 860 v and 860 wextending vertically along the side wall 234 of the housing to leadterminals OL1 u, OL1 v and OL1 w projecting from the holes 264 on a mainside wall 234 of the housing 210. In this embodiment, the bus bars 860u, 860 v and 860 w extend a side opposite to the inlet and outlet portsof the water path to be bypassed.

The alternating current terminal OT2 of the second power module 504 isconstituted by terminals OT2 u, OT2 v, OT2 w corresponding to respectiveU, V and W phases, and the terminals OT2 u, OT2 v, OT2 w are connectedthrough the bus bars 862 u, 862 v and 862 w extending vertically alongthe side wall 234 of the housing to lead terminals OL2 u, OL2 v and OL2w projecting from the holes 264.

The capacitor modules 302 and 304 and rotary motor control circuitsubstrate 700 are arranged above the power modules 502 and 504 and theswitching drive circuit substrate 602 and 604.

The power modules 502 and 504 have screw holes at their peripheries tobe fixed to the water path forming body 220 at the lower region of thehousing by screws SC1 through the screw holes.

Further, the drive circuit substrates 602 and 604 arranged above thepower modules 502 and 504 are fixed to the power modules 502 and 504 byscrews 2.

Further, in FIG. 9, the first drive circuit substrate 602 and the seconddrive circuit substrate 604 supply the switching signals to the firstpower module 502 and the second power module 504 respectively asdescribed above. Harnesses HN extend from the first drive circuitsubstrate 602 and the second drive circuit substrate 604 throughconnectors CN on their main surfaces to be connected to the rotary motorcontrol circuit substrate 700.

<Capacitor Module 300>

FIG. 10 is a plan view showing the housing 210 containing therein thecapacitor module 300 including the smoothing capacitors.

The capacitor module 300 includes the first capacitor module 302 and thesecond capacitor module 304 each of which is formed by arranging filmcapacitors (capacitor cells) of, for example, 5 or 6 in a rectangularcase made of, for example a resin material.

As shown in FIGS. 8 and 10, the first capacitor module 302 and thesecond capacitor module 304 are juxtaposed with each other so that thefirst capacitor module 302 is arranged above the first drive circuitsubstrate 602 and the second capacitor module 304 is arranged above thesecond drive circuit substrate 604.

The first capacitor module 302 and the second capacitor module 304 areelectrically connected to the direct current terminals of the first andsecond power modules 502 and 504 through connection parts JN (includingJN1 and JN2).

Incidentally, the first capacitor module 302 and the second capacitormodule 304 are electrically connected to a pair of the direct currentterminals of U phase arm, a pair of the direct current terminals of Vphase arm and a pair of the direct current terminals of W phase arm inthe power module 500. Therefore, each of the first power module 502 andthe second power module 504 are connected to corresponding one of thefirst capacitor module 302 and the second capacitor module 304 at 6positions as shown in FIG. 10. By this arrangement, inductances betweenthe capacitor modules and the power modules are decreased. The decreasein inductances causes an effect of that a temporary increase in voltageby the switching operation of the power modules is restrained.

In FIG. 10, each of the first and second capacitor modules 302 and 304has a pair of the electrodes TM1 and TM2 connected to the terminalbracket 810 for direct current to be connected to an outer directcurrent electric power source through the electrodes. The electrodes TM1and TM2 of each of the first and second capacitor modules 302 and 304are arranged a side of the housing 210 adjacent to the inlet and outletports of the water path. Since they are arranged in the common side inwhich the terminal bracket 810 for the direct current electric power isarranged in the terminal box 800, they are easily connected electricallyto the high voltage battery as the outer direct current electric powersource to improve the operability.

In FIG. 10, each of the first and second capacitor modules 302 and 304has at its four corners fixing holes FH1 and FH2 in which nuts areembedded respectively so that the first and second capacitor modules 302and 304 are fixed to the holder plate 320 by screws SC4 (refer to FIG.11) screwed into the fixing holes FH1 and FH2 through holes of theholder plate 320 corresponding to the fixing holes FH1 and FH2. That is,the first and second capacitor modules 302 and 304 are fixed to theholder plate 320 in a suspended manner.

<Holder Plate 320>

FIG. 11 is a plan view showing the housing 210 containing therein theholder plate 320 having thereon the rotary motor control circuitsubstrate 700. The holder plate 320 as a control substrate brackethaving the rotary motor control circuit substrate 700 is fixed to thehousing 210 above the capacitor module 300 in the housing 210.

A plurality of protrusions PR (refer to FIGS. 9 and 10) are arranged ina circumferential direction of the inner surface of the housing at asubstantially fixed interval so that upper end surfaces of theprotrusions PR support the holder plate 320 at its periphery, and theholder plate 320 is fixed by screws SC4 screwed into the upper endsurfaces of the protrusions PR through screw holes formed at theperiphery of the holder plate 320. Since the holder plate is supportedby a great area of the upper end surfaces of the protrusions arrangedcircumferentially, a high thermal conductivity between the housing andthe holder plate is obtained. The holder plate 320 is made of a metallicmaterial of high thermal conductivity such as aluminum materialsimilarly to the housing 210 to improve a mechanical strength. Further,a surface on which the rotary motor control circuit substrate 700 ismounted has a pattern of concavity and convexity.

The convexity of the holder plate 320 is formed to face to a surfacearea of the rotary motor control circuit substrate 700 on which electricwires or the like are formed so that the electric wires or the like areprevented from contacting the holder plate 320 of metallic material toprevent an electric short of the electric wires or the like. Further,the convexity as a recess is formed at a connection area for the directcurrent electric power source.

The convexity on a surface of the holder plate facing to the rotarymotor control circuit substrate 700 includes bosses BS distant from eachother as shown in FIG. 3 so that the rotary motor control circuitsubstrate 700 is fixed to the holder plate 320 by screws SC6 (refer toFIG. 16) screwed into the bosses through screw holes formed on therotary motor control circuit substrate 700.

As described above, the holder plate 320 holds fixedly the firstcapacitor module 302 and the second capacitor module 304 below it byscrews SC4 screwed into the fixing holes FH1 and FH2 at the four cornersof each of the first capacitor module 302 and the second capacitormodule 304 through the screw holes of the holder plate 320.

Accordingly, since the first capacitor module 302 and the secondcapacitor module 304 are fixed to the holder plate 320 contacting thehousing 210, a thermal energy generated by the first capacitor module302 and the second capacitor module 304 is easily transferred t thehousing 210 through the holder plate 320 to improve a heat radiatingeffect. Further, since the housing is cooled by the coolant water path,temperatures of the first capacitor module 302 and the second capacitormodule 304 are restrained from increasing.

<Rotary Motor Control Circuit Substrate 700>

FIG. 11 is a plan view showing the housing 210 containing therein therotary motor control circuit substrate 700 on the holder plate 320.

The rotary motor control circuit substrate 700 includes electric partsfor small signal as well as the connector CN. The connector CN isconnected through the harness HN to, for example, the connector CNmounted on the switching drive circuit substrates 602 and 604.

The rotary motor control circuit substrate 700 has screw holes at itsperipheral four corners and central area other than the parts and wiringlayer connecting the parts to be fixed to the holder plate 320 by screwsSC6 screwed into the holder plate 320 through the screw holes.

Therefore, the rotary motor control circuit substrate 700 can berestrained from being deformed at its central area by vibration or thelike, in comparison with a case in which only its peripheral area isfixed to the frame.

As describe above, since the rotary motor control circuit substrate 700is mounted on the holder plate 320 contacting the housing 210, the heatenergy generated by the rotary motor control circuit substrate 700 isefficiently transferred to the housing 210 through the holder plate 320to improve the heat radiating effect.

<Cover 290>

The cover 290 close the opening of the housing 210 after the first andsecond power modules 502 and 504, switching drive circuit substrates 602and 604, first and second capacitor modules 302 and 304, holder plate320 and rotary motor control circuit substrate 700 are received in thehousing 210.

The cover 290 is made of a material similar to that of the housing 210,and is fixed to the housing 210 (refer to FIG. 5) by screws SC 7 screwedinto the upper end surfaces of the housing 210 through screw holesarranged circumferentially at the substantially constant interval on itsperiphery.

<Cooling Structure of First and Second Power Modules 502 and 504>

As described above, the coolant water path is formed at the bottom ofthe power converter 200. FIG. 12 is a structural view seen upward fromthe bottom of the housing 210 to show a water path holder member 902 asa part of the water path forming body 220. The water path holder member902 has an outer peripheral part 904 on which a bottom plate as anotherpart of the water path forming body 220 is mounted, and the outerperipheral part 904 includes holes SC 9 for screw fixing. Some of themhave denoting numbers, and the other of them have no denoting number. Aseal groove 906 is arranged at an inner side of the outer peripheralpart 904 to prevent the water leakage, and the water path holder member902 at the inner side of the seal groove 906 has outer regions 912 atits both sides, as well as the first and second water paths 922 and 924and central area 908 referred to as the coolant water path 216 in theprevious drawing. An O-ring or rubber seal is fitted into the sealgroove and the screw holes) are tightened by the screws to obtain theseal function. The coolant water is supplied to an inlet part 916 of thewater path 922 (previously referred to as 216), the coolant water flowsthrough the first water path 922 in a direction of arrow, a flowdirection of the coolant water is changed in U-shape by a fold back path924 to flow through the second water path in the direction of arrow, andthe flow is discharged from a discharge port 918 of the water path 924.The first and second water paths 922 and 924 have openings 218 and 219as holes. By attaching the bottom plate 934 in FIG. 13 as describedbelow, the water paths 922 and 924 are formed and the openings 218 and219 open to the water paths.

The central part 908 between the first water path 922 and the secondwater path 926 and the outer region 912 between the first water path 922and the outer peripheral part 904 and between the second water path 926and the outer peripheral part 904 have recesses 932 to decrease athickness of molded aluminum.

In FIGS. 13(A) and (B), the bottom plate 934 closing the bottom of thehousing 210 shown in FIG. 12 is shown. The bottom plate 934 and the arewater path forming members to allow the water to flow as shown by thearrow in FIG. 13(A). The bottom plate 934 has the screw holes SC9 to bepressed by screws through the screw holes SC9 at the outer periphery 904of the water path holder member 902. The bottom plate 934 has firstprotrusion 935 and second protrusion 936 so that the protrusion 935 isinserted into the water path 922 and the protrusion 936 is inserted intothe water path 926. Incidentally, a recess is formed to decrease thethickness of molded aluminum.

A cross section of the water path 922 along II-II section in FIG. 12 isshown in FIG. 14. Incidentally, the water path 926 has the substantiallysame shape in FIGS. 12, 13 and 14, the water path holder member 902includes water paths 922 and 924 parallel to each other. The coolantwater is introduced from the inlet pipe 212 (not shown in FIG. 12) intoan inlet part 916. The inlet part 916 of the water path includes ametallic roof 882 monolithically formed with the housing 210, andmetallic side walls 988 and 990 monolithically formed with the housing210 are arranged at both sides of the water path. A width of the waterpath increases gradually and a depth thereof decreases gradually at adownstream side of the inlet pipe as shown in FIG. 12. Therefore, theflow of the coolant water is made smooth to restrain bubbles from beinggenerated and to decrease a flow resistance. The water is introducedfrom the inlet part into the water path with the opening. The water pathwith the opening has a protrusion 935 at its bottom as shown in FIG. 13so that the bottom of the water path is elevated and the depth of thewater path is slightly deeper than a height of the heat radiating fin.The height of the heat radiating fin is 6-8 mm, and the depth of thewater path is not more than 10 mm, preferably not more than 9 mm.

The opening 218 is formed on a side of the water passage forming body220 opposite to the protrusion 935, and the heat radiating fin 506 onthe base plate 944 of the power module 502 projects into he opening 218while the power module 502 is fixed by the screws SC1. Although notshown in the drawings, the power module 504 is fixed onto the opening ofthe water passage forming body 220 in which the other water path 926 isformed. Accordingly, a thermal conductivity between the heat radiatingfin and the water as the coolant is improved. Further, the fold backportion as a joint between the water paths 922 and 926 juxtaposed witheach other has a depth deeper than that of the region in which the finprojects to decrease the flow resistance to facilitate the coolant flow.

The power module 504 has the substantially same structure as the powermodule 502 as described below, and is fixed similarly, whereby only thepower module 502 is explained. The plurality of the heat radiating fins506 (three heat radiating fins in this embodiment) project into thewater path from the opening 218 of the water path 922. The heatradiating fins 506 are arranged on one of the surfaces of the metallicbase plate 944, and the semiconductor chips are mounted on the other oneof the surfaces of the metallic base plate 944. The semiconductor chipsare sealed by a resin case 946. Such structure is common with arelationship between the power module 504 and the water path 926.

The power module 502 is fixed with the metallic plate 982 by the screwsSC1 to the water path forming body forming the water path as shown inFIGS. 9 and 14 in this embodiment, it is fixed to the water path cover882 formed monolithically with the housing 210. The power module 502fixed by the screws closes at its heat radiating surface the opening 218of the water path 922. A sealing member such as O-ring 986 is arrangedbetween the heat radiating surface of the power module 502 and the waterpath forming body around the opening to prevent the water leakage.

A heat radiating plate 984 of metallic or resin material of high thermalconductivity is arranged to opposite to the metallic plate 982, and thedrive circuit substrate 602 is arranged to opposite to the heatradiating plate 984. The thermal energy of the drive circuit substrate602 is transmitted to the water path forming body through the heatradiating plate 984 to be transmitted to the coolant water so that atemperature of the drive circuit substrate 602 is restrained fromincreasing. The above structure and functional effect are alsoobtainable in the power module 504 and the drive circuit substrate 604.

FIG. 15 is an enlarged partial view along III-III section of FIG. 14.The bottom plate 934 is arranged at the bottom of the water path formingbody 220 to form the water path 922. Both sides of the water path aredefined by side plates 988 and 990 monolithically formed with thehousing 210. A sealing between the side plates 988 and 990 and the waterpath forming body 220 is performed by a sealing member 986 such asO-ring or gasket whose width is greater than the O-ring. The opening 218above the water path 922 is closed by the heat radiating surface of themetallic base plate 944 of the power module 502 as described above. Thesealing member 986 such as O-ring or gasket whose width is greater thanthe O-RING is used for the sealing. The plurality of the semiconductorchips are fixed to the other surface of the metallic base plate 944 andsealed by the resin case 946.

The drive circuit substrate 602 is fixed by the screws SC2 onto thepower module 502 through the heat radiating plates 982 and 984.

In the above description, as shown in FIG. 14, the water path is madedeep at the inlet, outlet and fold back portions, and the region inwhich the heat radiating fin is inserted is made shallow in comparisonwith the above portions. The depth of the water path at the region inwhich the heat radiating fin is inserted is slightly greater than theheight of the heat radiating fin. In this embodiment, the height of theheat radiating fin is 6-8 mm the depth of the water path is not morethan 10 mm, preferably not more than 9 mm. The above structure andfunctional effect is also obtainable in the power module 504 and thewater path forming body including the water path.

<Power Module>

The power module 5-2 or 504 as seen from the fin side is shown in FIG.17, and the power module 5-2 or 504 from which the resin case is removedis shown in FIG. 16. Further, a IV-IV cross section in FIG. 16 is shownin FIG. 18. Although three cross sections of the semiconductors areshown actual cross sectional view, for intelligible explanation, two ofthe semiconductor chips are deleted, and one of the semiconductor chipsas being enlarged is shown.

Three sets of the heat radiating fins 506A, 506B and 506C are mounted onthe heat radiating surface of the metallic base plate as shown in FIG.17. The O-ring or gasket as the seal member 986 for preventing theleakage of the coolant water from the water path is arranged on the heatradiating surface around the outer periphery of the heat radiating fin.The openings of the water path 922 (216) and 926 (216) are closed by thebase plate 944 whose heat radiating surface is pressed against theopenings of the water path by the screws, and the seal member 986prevents the leakage of the coolant water from the water path.

The heat radiating fin is fixed by a brazing material 948 as shown inFIG. 18. The brazing is carried out in, for example, 600-700° C. Theinsulating substrate 956 is adhered by a second solder layer 962 to thereverse surface of the metallic base plate 944 to opposite to the threesets of the heat radiating fins.

The metallic base plate 944 is an alloy including a main component ofcopper and impurities. It preferably has a hardness not less than HV 50after the heat radiating fin is fixed by the brazing and a thermalconductivity not less than 200 W/mK. A thickness of the base plate is2-4 mm. The flatness at a part thereof overlapping the insulatingsubstrate or surrounded by the fixing screw holes 978 is preferably notmore than 0.2 mm or is not more than 0.1 mm as optimum value. Further,the flatness at the other part thereof overlapping the six insulatingsubstrates or the semiconductor chips forming the inverter is preferablynot more than 0.4 mm or is not more than 0.3 mm as optimum value. Whenthe copper includes the impurity harder than the copper, the hardnessthereof increases in accordance with an increase in rate thereof. On theother hand, since the impurities are of lower thermal conductivity thancopper, the thermal conductivity as the whole decreases. Therefore, itis preferable for the rate of the impurities to be adjusted to maintainthe hardness and the thermal conductivity. Further, it is preferable forthe base plate to be plated with nickel of thickness of about 3-9 μm. Asshown in FIG. 18, the heat radiating fin 506 is attached to one ofsurfaces thereof by brazing and the insulating substrate of thesemiconductor chips is attached to the other one of surfaces thereof bysoldering. There is a probability of that the surface of cupper includesscratch, whereby the plating of suitable thickness enables the surfaceroughness to be kept suitable. In this embodiment, it is preferable forthe region where at least the insulating substrate is mounted and theO-ring is arranged to have the surface roughness for satisfying Ra=3.2.

<Production of Semiconductor Module>

In FIG. 18, the metallic heat radiating fin 506 is attached by brazingin 600-700° C. to the base plate of alloy with the main component ofcopper satisfying the above condition. In a certain case, it becomes800-900° C. If the base plate 944 is soft, the flatness is deterioratedby the brazing to make the subsequent adhesion of the insulatingsubstrate difficult. The containing rate of the impurities is adjustedappropriately to have the hardness not less than HV50 and the thermalconductivity not less than 200 W/m after the brazing. As shown in FIG.16, the three fins 506A-C are fixed by the brazing.

In another process, the semiconductor chips 952 are adhered to theinsulating substrate 956 by high melting point solder. A first solderlayer 958 is formed by this process to fix the semiconductor chips 952to the insulating substrate. The solder layer is a layer of the highmelting point solder, and is not melted during an adhesion process witha second solder layer of low melting point solder. As shown in FIG. 16,three sets of diode chips 954 and three sets of IGBP chips 952 areadhered to the insulating substrate 956. The denoting codes are attachedonly to the insulating substrate 956, and those for the other insulatingsubstrate are not shown. The insulating substrates each including thethree sets of diode chips 954 and the three sets of IGBP chips 952 arearranged in parallel to face to each other to correspond to one of U, Vand W phases and one of the fins adhered to the reverse surface of thebase plate 944. The base plate 944 shown in FIG. 16 includes the threeinsulating substrates arranged in parallel to face to each other to formthe inverter for three phases. The insulating substrates have theidentical structure.

After the above process, the insulating substrates of six to each ofwhich the semiconductor chips 952 of three sets are adhered are adheredby the second solder 962 of low melting point to the base plates 944including the heat radiating fins of three to have a positionalrelationship thereamong as shown in FIGS. 16 and 17. That is, they areattached in such a manner that the insulating substrates of two oppositeto the fin of one through the base plate 944. In FIG. 18, the heatradiating fin 506 and the base plate 944 are adhered to each other bythe brazing at the highest adhering temperature. The semiconductor chips952 are adhered to the insulating substrate 956 by the high meltingpoint solder at a second temperature lower than the highest adheringtemperature. The insulating substrate 956 is adhered to the base plateby the low melting point solder at a temperature lower than the secondtemperature. Since the highest adhering temperature for adhering theheat radiating fin 506 by the brazing is high, if the base plate 944 isnot formed of the metallic material harder than the pure copper, theflatness of the reverse surface of the base plate 944 is deteriorated tomake the adhesion of the insulating substrate difficult. If the contentof the metallic impurity is increased, the flatness can be easily kept,but the thermal conductivity decreases to decrease the coolingefficiency of the insulating substrate 956. A condition for obtainingboth of the characteristics is that the hardness after the brazing isnot less than HV 50, and the thermal conductivity after the brazing isnot less than 200 W/mK. Further, it is optimum that the flatness in theregion of each of the insulating substrates is not more than 0.1 mm, andit is preferable that the flatness is not more than 0.2 mm. Further, itis desired that the area of the base plate to which the insulatingsubstrates of six are adhered is kept high in flatness, it is optimumthat the area (to which all of the insulating substrates are adhered) towhich the insulating substrates of six are adhered has the flatness notmore than 0.3 mm, and it is preferable that the flatness is not morethan 0.4 mm close to 0.3 mm.

In another concept, it is optimum that an area defined by the attachingscrews 978 has the flatness not more than 0.1 mm, and it is preferablethe flatness is not more than 0.2 mm.

In this embodiment, the plurality of the insulating substrates 956 arearranged on the base plate 944, and an arrangement for bearing highvoltage on each of the semiconductor chips in each of the insulatingsubstrates is kept. Accordingly, for example, in the insulatingsubstrate including the plurality of the semiconductor chips forconverting the direct current electric power of voltage not less than300 V to the alternating current electric power, an area of theinsulating substrate is great, it is preferable that the flatness in thearea to which each of the insulating substrates 956 is adhered is notmore than 0.2 mm, and it is optimum that the flatness is kept not morethan 0.1 mm.

As shown in FIG. 16, the semiconductor chips of three sets adhered tothe insulating substrate are, in this embodiment, IGBT (Insulated GateBipolar Transistor) chips and diode chips, and chips 952 in FIG. 18 areIGBT chips. The diode chips 954 adjacent to the IGBT chips have thestructure as shown in FIG. 18, and are adhered to the insulatingsubstrate 956 by the same process. A difference is that the diode chipsare used as the semiconductor chips. The IGBT chips of three and thediode chips of three are adhered to each of the insulating substrates bythe high melting temperature solder, and the insulating substrate of sixeach including these semiconductor chips of six are adhered to the baseplate 944 with an arrangement shown in FIG. 18 by the low melting pointsolder.

In the above embodiment, the IGBT chips are used as the semiconductorchips 952, but MOS transistor chips may be used. In this case, the diodechips do not need to be used.

In FIGS. 16, 17 and 18, holes 978 are used to attach the semiconductormodule to the path forming body 220.

FIG. 19 wherein the heat radiating fin 506 has a pin shape is anembodiment other than that of FIG. 18. It is attached to the base plate944 by the brazing similarly to the radiating fin 506 of wave shapeshown in FIG. 18. The fin of pin shape is adhered to the metallic baseplate by the brazing material layer 948. In this embodiment, a height ofthe pin as the heat radiating fin from the base surface is 6-8 mm. Thedepth of the water path at the area in which the heat radiating fin isinserted as shown in FIG. 14 is not more than 10 mm, preferably not morethan 9 mm. A number of the pins in each area of the pins, that is, thearea 506A in FIG. 17, is 300-700. A diameter of the pins is 3-5 mm witha height of 0.5-1.5 mm at the brazed portion, a diameter of its higherpart is 2-3 mm. These pins are arranged in a staggered form.

FIGS. 20(A)-(C) are outer views of the power module 502 or 504. FIG.20(A) is a plan view of the power module 502 or 504, FIG. 20(B) is aside view thereof, and FIG. 20(C) is a front view thereof. As describedabove, the power module shown in FIGS. 16 and 17 does not include theresin case shown in FIG. 20. Incidentally, the heat radiating fin 506 inFIGS. 16 and 17 has the wave shape other than the pin shape. In FIG.20(A) as the plan view, the terminals OTiu, OTiv and OTiw for thealternating current to be connected to the rotary motor are arranged atan end. Thee sets of terminals IT1N and IT1P for the direct current tobe connected to the direct current electric source are arranged atanother end as opposite side. These terminals are arranged as shown inFIG. 9 to be connected to the terminals of the capacitor incidentally,the terminal IT1N is connected to a negative side of the direct currentelectric source, and the IT1P is connected to a positive side of thedirect current electric source. The terminals for the positive side areelectrically connected to each other in parallel, and the terminals forthe negative side are electrically connected to each other in parallel,in the three sets of the terminals IT1N and IT1P for the direct currentin FIG. 20.

Datum pins 992 are arranged to position the drive circuit 602 or 604fixed to the power modules 502 or 504.

FIG. 21 shows a positional relationship between the power module 502 andthe power module 504 with the radiating fins thereof fixedly projectingin the openings 219 and 219 of the water path 022 and 926. An arrow markshows a direction of water flow in the water path. The power module 502and the power module 504 are arranged in parallel while those terminalsfor the direct current are arranged at the inside. This arrangementenables the connection to the terminals of the capacitor at the centralregion so that the structure of the apparatus is simplified as thewhole. Further, the connection to the capacitor modules 302 and 304 canbe obtained through short length of the interconnection lines with thepositive and negative sides for the direct current facing to each otherso that an inductance of the interconnection lines is decreased torestrain a surge of voltage caused by the switching operation of thepower modules 502 and 504.

Further, in this apparatus, IP1P and IT2P are connected to the positivepole of the direct current electric power source, and IP1N and IT2N areconnected to the negative pole of the direct current electric powersource. As shown in FIG. 21, the power modules 502 and 504 are arrangedin parallel with a small shift therebetween so that the power modules502 and 504 can have the identical shape. Further, a distance of theinterconnection is shortened to decrease the inductance. N terminals ofthe power modules 502 and 504 can be arranged to be close to each other,and P terminals of the power modules 502 and 504 can be arranged to beclose to each other. Therefore, an arrangement of the interconnectionlines are simplified to decrease the inductance and make the wiringoperation easy.

Since the terminals OT1 and OT2 for alternating current to be connectedto the rotary motor are arranged at the outside of the power module 502or 504 arranged in parallel, bus bars for connecting the terminals OT1and OT2 for alternating current to another rotary motor can be easilyarranged. The structure of the apparatus is simple as the whole toimprove operability.

<Explanation of Electric Circuit>

FIG. 22 is a view of a circuit of the power converter 200 of theembodiment, and the power converter 200.includes the first power module502 as the inverter, the second power module 504 as the inverter, thecapacitor module 300, the drive circuit 92 mounted on the first drivecircuit substrate 602 of the inverter, the drive circuit 94 mounted onthe second drive circuit substrate 604 of the inverter, the controlcircuit 93 mounted on the rotary motor control circuit substrate 700, aconnector 73 mounted on the connector substrate 72, a drive circuit 91for driving the electric discharge circuit (not shown) of the capacitormodule 300, and electric current sensors 95 and 96.

Incidentally, in FIG. 22, the electric power source system is indicatedby solid lines, and the signal system is indicated by dot-lines toclearly distinguish the electric power source system and the signalsystem from each other.

The first power module 502 and the second power module 504 form a maincircuit for converting the electric power in the correspondinginverters, and each of then includes a plurality of power semiconductorelements for switching. The first power module 502 and the second powermodule 504 are operated by driving signals output from the drivingcircuits 92 and 94 respectively to convert the direct current electricpower supplied from the high voltage battery 180 to three-phasealternating current electric power to be supplied to respective rotorcoils of the rotary motors 130 and 140. The main circuit is athree-phase bridge circuit as shown in FIG. 22, and the series circuitsfor the three phases are connected in parallel between the positive poleside and the negative pole side of the battery 180. The series circuitis formed by semiconductor chips 952 adhered to the insulatingsubstrates 956 facing to each other. The semiconductor chips of thefirst power module 502 and the second power module 504 as shown in FIG.22 are arranged as shown in FIG. 16.

<Explanation of Second Power Module 504>

The first power module 502 and the second power module 504 have theidentical circuit arrangement as shown in FIG. 22, whereby the secondpower module 504 is explained as the representative. In this embodiment,IGBT (isolated gate type bipolar transistor) 21 is used as the powersemiconductor element for switching. The IGBT 21 has a collectorelectrode, an emitter electrode and a gate electrode. A diode 38 isconnected to the collector electrode and the emitter electrode. Thediode 38 has a cathode electrode connected to the collector electrode ofthe IGBT 21 and an anode electrode connected to the emitter electrode ofthe IGBT 21 so that a forward direction is directed from the emitterelectrode to the collector electrode in the IGBT 21. The IGBT 21corresponds to the semiconductor chip 952 in FIGS. 16, 18 and 19, andthe diode 38 corresponds to the diode chip 954 in the above drawing. Asexplained above, MOSFET (metal oxide semiconductor field-effecttransistor) may be used as the power transistor for switching. TheMOSFET has three electrodes of drain electrode, source electrode andgate electrode. Incidentally, the MOSFET includes a parasitic diode theforward direction is directed from the drain electrode toward the sourceelectrode between the source electrode and the drain electrode, it doesnot need to include an additional diode needed by the IGBT.

The arm of each phase is constituted by the source electrode of the IGBT21 and the drain electrode of the IGBT 21 electrically connected to eachother in series. Incidentally, in this embodiment, although only theIGBT of each of upper and lower arms of each phase is shown, theplurality of the IGBTs are electrically connected in parallel to controla great amount of the electric current. In the embodiment shown in FIG.22, each of the upper and lower arms of each phase is constituted bythee of the IGBTs. The drain electrode of the IGBT 21 of each of theupper arms of each phase is electrically connected to the positive poleside of the battery 180, and the source electrode of the IGBT 21 of eachof the lower arms of each phase is electrically connected to thenegative pole side of the battery 180. The terminals of thesemiconductor modules 502 and 504 to be connected to the positive poleside of the battery 180 are denoted by IT1P and IT2P in FIGS. 20 and 21.Further, the terminals of the semiconductor modules 502 and 504 to beconnected to the negative pole side of the battery 180 are denoted byIT1N and IT2N in FIGS. 20 and 21.

A central point of the each of the arms of each phase (a joint portionbetween the source electrode of IGBT of upper arm side and the drainelectrode of IGBT of lower arm side) is electrically connected to therotor coil of corresponding phase of corresponding one of the rotarymotors 130 and 140. The central points are denoted by OT1 u, OT1 v, OT1w, OT2 u, OT2 v and OT2 w in FIGS. 20 and 21.

The drive circuits 92 and 94 are driving parts of the respectiveinvertors to generate driving signals for driving the IGBT 21 inaccordance with the control signal output by the control circuit 93. Thedriving signal generated by the circuit 92 or 94 is output to thecorresponding one of the first power module 502 and the second powermodule 504. The drive circuits 92 and 94 are constituted by anintegrated circuit containing as single block the plurality of thecircuits corresponding to the upper and lower arms of each phase todrive six of the IGBTs. The circuits corresponding to the upper andlower arms of each phase includes interface circuits, gate circuits,abnormality detecting circuits and so forth.

The control circuit 93 is a micro-computer calculating the controlsignal (control value) to operate (on-off) the plurality of the powersemiconductor elements for switching as a controller of each of theinvertors. A torque ordering signal (torque ordering value) and signals(sensor output) detected by electric current sensors 95 and 95 androtary sensors mounted on the rotary motors 130 and 140 are input intothe control circuit 93. The control circuit 93 calculates the controlvalues on the basis of these input signals to output the control signalsfor controlling the switching timing of the drive circuits 92 and 94.

The connector 73 connects electrically the power converter 200 and theexternal controller to each other to input and output the information toand from another apparatus through the communication line 174 in FIG. 1.

The capacitor module 300 has capacitor modules 302 and 304 shown in FIG.10 as the smoothing circuit for restraining the variation of the directcurrent voltage caused by the switching operation of the IGBTs 21, andis electrically connected in parallel to the terminals at the directcurrent side of the first power module 502 and the second power module504.

The drive circuit 91 drives the electric discharge circuit (not shown)to discharge electric charge stored in the capacitor module 300.

Second Embodiment

Next, with making reference to FIGS. 23-28, the second embodiment isexplained. The above described circuits shown in FIG. 22, the structureof the power module shown in FIGS. 16-21 and the basis structure of thecoolant water path shown in FIGS. 12-15 are common with respect to thesecond embodiment. A difference is that the power converter 200 of thefirst embodiment has the coolant water paths 922 and 926 at the bottom,the power converter 200 of the second embodiment has the coolant waterpaths at the middle area. In the second embodiment, the electric partsto be cooled such as the power modules 502 and 504 and the capacitormodules 302 and 304 are mounted on both surfaces of the coolant waterpath forming body so that the cooling is performed at the both surfaces.For example, the semiconductor modules such as the power modules 502 and504 are mounted on one of the surfaces of the coolant water path formingbody to be cooled, and the capacitor modules 302 and 304 are mounted onthe other one of the surfaces of the coolant water path forming body tobe cooled.

The second embodiment of the power converter is described below. Thepower converter 200 is fixed with a stacked manner in which a secondbase 12 is mounted on the lower case 13, the first base 11 is mounted onthe second base 12, and the upper case 10 is mounted on the first base11. An outer appearance of the power converter 200 as the fixedlystacked housing has a generally rectangular shape with rounded corners.The components of the housing is made of high thermal conductivitymaterial such as aluminum. The housing has basically the sameperformance as the housing 210 explained as the first embodiment, andincludes the lower case 13 and the upper case 10. The water path formingbody constituted by the first base 11 and the second base 12 is fixed tothe central portion of the housing formed by the cases, and the electricparts such as the power modules and the capacitor modules are mounted onthe both surfaces of the water path forming body as described below.

The housing is surrounded at its whole periphery (peripheral wall, roofwall and bottom wall) by a member of high thermal conductivity such asaluminum, and the coolant water path formed by the first and secondbases 11 and 12 is fixed to the housing with a high thermal conductivitystructure so that the housing is effectively cooled. In the housing, thecoolant water path is formed by the water path forming body constitutedby the first and second bases 11 and 12 so that upper and lower chambersof the water path forming body are formed in the housing. The water pathforming body includes two cooling water paths 922 and 926 in parallelfor a flow of the coolant water as the coolant. By the above describedstructure, the two chambers are thermally isolated from each other bythe coolant water path to restrain a thermal interference between thechambers. Further, the rooms and room walls are cooled respectively.

In the upper chamber of the water path forming body, the first powermodule 502 and the second power module 503 are juxtaposed with eachother along the longitudinal direction of the housing as shown in FIGS.24 and 28. The openings 218 a and 219 are formed on the coolant waterpath 922 and 926 as shown in FIGS. 12 and 13, and the openings 218 and219 are closed by the heat radiating surfaces of the base plates 23 ofthe first power module 502 and the second power module 503 so that thefirst power module 502 and the second power module 503 are cooledefficiently. Further, the heat energy discharged from the first powermodule 502 and the second power module 503 is restrained from affectingthermally the lower chamber.

The inlet pipe 212 and outlet pipe 214 communicating with the coolantwater path 922 and 926 are arranged at one of side surfaces of thehousing aligned in its longitudinal direction as shown in FIG. 27. Thecoolant water path 922 and 926 extend parallel to each other along thelongitudinal direction of the housing, and are bent to communicate witheach other at the other end in the longitudinal direction of thehousing. The shape of the water path shown in FIGS. 12-14 and the shapeof the water path of the second embodiment are substantially identicalto each other.

The openings 218 and 219 (refer to FIG. 28) are arranged on the coolantwater path 922 and 926 of the first base 11, the heat radiating finsarranged on the power module 502 and the second power module 504 projectinto the water path from the openings 218 and 219, and the openings 218and 219 are closed by the base plate 3 of the power modules 502 and 504.The fins are directly cooled by the coolant, and the base plate 23 isefficiently cooled by the coolant flowing in the coolant path (waterpath 922 and 926).

The base plate 23 is identical in shape and functional effect to thebase plate 944 as shown in FIGS. 18 and 19, made of metallic material ofhigh thermal conductivity with a main component of copper, and the heatradiating fins projecting into the coolant path (water paths 922 and926) are attached to a surface facing to the coolant path. The heatradiating fins are identical in structure to the heat radiating fins 506and 507 shown in FIGS. 18 and 19 to increase a surface area cooled bythe coolant so that a cooling effect by the coolant is improved.

As shown in FIG. 28, the coolant water supplied from the inlet pipe 212is made deep at the inlet part of the first water path 922, andsubsequently is made shallow at the area of the first water path atwhich the heat radiating fin 506 projects. The fold back portion of thewater path as the joint between the first water path 922 and the secondwater path 926 is made deeper in comparison with the area at which theheat radiating fin 506 projects, and the area of the second water path926 at which the heat radiating fin 507 projects is made shallow. Theoutlet part of the second water path 926 is made deeper in comparisonwith the area at which the heat radiating fin projects, and is connectedto the outlet pipe 214. The shape and functional effect of this waterpath is identical to the shape shown in FIGS. 12, 13 and 14, a heatexchange of the coolant water is efficiently performed at the area atwhich the heat radiating fin projects, and the flow resistance isdecreased at the area the heat radiating fin does not project so thatthe cooling efficiency of the cooling system as the whole is improved.

The metallic base plates 23 of the power modules 502 and 504 closerespectively the openings of the water paths, and the resin case 24shown in FIGS. 15-21 is arranged on the upper surface of the base plates23. The resin case 24 shown in FIGS. 23-28 are identical to the resincases 946 shown in FIGS. 14, 15 and 20. Incidentally, in FIGS. 23, 24and 28, the upper cover of the resin case 24 of the first power module502 is eliminated to clearly show the inside of the power module 502.Further, only central two of combinations of the semiconductor chips andinterconnection line arrangements adhered to the six insulatingsubstrates 22 of the first power module 502 at right column in FIG. 24are shown, but the other four of the semiconductor chips adhered to theinsulating substrates 22 are eliminated.

The module terminals 26 (refer to FIG. 24) of the direct currentpositive pole side and the module terminals 33 (refer to FIG. 24) of thedirect current negative pole side are arranged on the side wall of theresin case extending in its longitudinal direction and facing to thefirst power module 502 and the second power module 504 to correspond torespective containing chambers. The module terminals 33 of the directcurrent positive pole side and the module terminals 26 of the directcurrent negative pole side project upward from the side of the resincase 24. Sides of the module terminals 33 of the direct current positivepole side and the module terminals 26 of the direct current negativepole side opposite to their projecting side extend into the containingchambers and their surfaces are exposed on the surface of the resincase. Therefore, the module electrodes 36 of the direct current positivepole side and the module electrodes 37 of the direct current negativepole side are formed in the containing chambers. The terminals 26 areidentical to the terminals IT1P and IT2P of the first embodiment shownin FIGS. 20 and 21, and the terminals 33 are identical to the terminalsIT1N and IT2N shown in FIGS. 20 and 21.

The alternating current module terminals 27 (refer to FIG. 24) arearranged on another side wall of the resin case extending in itslongitudinal direction and arranged opposite to the side facing to thefirst power module 502 and the second power module 504. The alternatingmodule terminals 27 project upward from the side wall of the resin case.The sides of the alternating current module terminals 27 opposite totheir projecting side extend into the containing chambers, and thesurfaces thereof are exposed on the surface of the resin case 24.Therefore, the alternating current module terminals 35 are formed in thecontaining chambers. The terminals 27 for the alternating current areidentical in shape and functional effect to the terminals OT1 u, OT1 v,OT1 w, OT2 u, OT2 u, OT2 v and OT2 w of the first embodiment shown inFIGS. 20 and 21.

The insulating substrates 22 of two are juxtaposed with each other inthe longitudinal direction of the housing on the upper surface of thebase plates 23 of the containing chambers. The wave-shapedinterconnection line members 39 of two are juxtaposed with each other inthe longitudinal direction of the housing on the upper surface of eachof the insulating substrates 22. Sides of the interconnection linemembers 39 arranged a side of the two insulating substrate 22 of thecontaining chamber are electrically connected to the module electrodes36 of the direct current positive pole side. The sides of theinterconnection line members 39 arranged at the other side of the twoinsulating substrate 22 of the containing chamber are electricallyconnected to the module electrodes 38 of the direct current negativepole side. The other sides of the interconnection line members 39 areelectrically connected to the alternating current module electrodes 35.These electric connections are performed by electrically conductivewires 29.

Three sets of the IGBT 21 and the diode 38 juxtaposed with each other inthe longitudinal direction of the housing are juxtaposed with each otherin the transverse direction of the housing on the upper surface of oneside of the interconnection line members 39 arranged on the twoinsulating substrates 22 in the containing chambers. Therefore, theupper and lower arms of each phase are formed. The IGBT 21 and thediodes 38 are electrically connected to the interconnection line members39 electrically connected to the alternating current module electrodes35. The gate electrodes of the IGBT 21 are electrically connected to theconnectors 25. These electric interconnections are performed by theelectrically conductive wires 29. The connectors are arrangedrespectively on four side walls forming three regions of the uppersurface of the base plate 23 of the resin case. The arrangement of theIGBT 21 and the diodes 38 is identical to the arrangement shown in FIG.16. The insulating substrate 22 of the second embodiment is identical tothe insulating substrate 956 of the first embodiment to perform the samefunctional effect.

The module case cover 34 of plate shape is arranged on the upper part ofthe resin case. The module case cover 34 forms the roof wall closing theupper opening of the resin case to close the containing chamber, and ismade of the same material as the resin case. The interconnection linesheet 31 and the interconnection line connector 32 electricallyconnected to the interconnection line sheet 31 are arranged on the uppersurface of the module case cover 34. The interconnection line sheet 31is electrically connected to the connectors 25 projecting upward fromthe through holes of the module case cover 34. The interconnection lineconnector 32 is electrically connected to the drive circuits of thefirst drive circuit substrate 70 and second drive circuit substrate 71by interconnection line not shown. The drive circuits are identical tothe drive circuits 92 and 94 shown in FIG. 22, and are identical to thecircuits of the drive circuits substrates 602 and 604 of the firstembodiment.

The capacitor module 300 is arranged in the cooled chamber at the lowerportion of the housing. The capacitor 300 includes the capacitor modules302 and 304 similar to the condenser module 300 in the first embodimentor the circuit of FIG. 22.

The capacitor module 300 is arranged to position the electric terminalsat the lower side of the central region (defined by two legs of π) ofthe second base 12 in the vicinity of the direct current side terminalsof the first power module 502 and the second power module 504. Thecapacitor module 300 is constituted by four electrolytic capacitors ofelliptical cross sectional shape in the height direction of the housing.The four electrolytic capacitors are arranged to juxtapose two of themin each of the longitudinal direction and the transverse direction whilethose longitudinal directions are parallel to the longitudinal directionof the housing, and are contained in the capacitor case 51 through theholder band 52. The capacitor case 51 is a thermally conductivecontainer whose upper part is opened, and the lower ends of the two legsof π contact a flange of the upper part of the case. Therefore, thecapacitor modules 300 and the coolant path (water paths 922 and 926) arethermally connected to each other with high thermal conductivity to coolsufficiently the capacitor module 300.

Each of the electrolytic capacitors has a positive pole side capacitorterminal 57 and a negative pole side capacitor terminal 56 extendingthrough a capacitor cover 54 closing the opening of the upper part ofthe capacitor case 53. The positive pole side capacitor terminal 57 andnegative pole side capacitor terminal 56 of plate shape face to eachother in the transverse direction to arrange an insulating member 55 ofplate shape formed monolithically with the capacitor cover 54 betweenthem. The capacitor terminals are arranged to differentiate longitudinalpositions thereof adjacent to each other in the transverse directionfrom each other when the four electrolytic capacitors are contained bythe capacitor case 53.

The first drive circuit substrate 70 is arranged in a region surroundedby one of the legs of π and the flange of the second base 12 in thelower side of the second base 12 adjacent to the power module 502. Thesecond drive circuit substrate 71 is arranged in a region surrounded bythe other one of the legs of π and the flange of the second base 12 inthe lower side of the second base 12 adjacent to the power module 504.The drive circuit substrates 70 and 71 are thermally connected to eachother. Therefore, the coolant path and the drive circuit substrates 70and 71 are thermally connected to each other to cool the drive circuitsubstrates 70 and 71 with the coolant water as the coolant.

The rotary motor control circuit substrate 74 faces to a side surface ofthe capacitor case 53 at one of sides thereof in the transversedirection (adjacent to the second power module 504). The rotary motorcontrol circuit substrate 74 is thermally connected to the second base12. Therefore, the coolant path (water paths 922 and 926) and the rotarymotor control circuit substrate 74 are arranged with high thermalconductivity to cool efficiently the rotary motor control circuitsubstrate 74 with the coolant.

The connector substrate 72 faces to a side surface of the capacitor case53 at the other one of sides thereof in the transverse direction(adjacent to the first power module 502). The rotary motor controlcircuit substrate 72 is thermally connected to the second base 12.Therefore, the coolant path 28 and the connector substrate 72 arethermally connected to each other to cool the connector substrate 72with the coolant. The connector 73 projects outward from the side endsurface of the other side of the housing in the longitudinal direction.

The capacitor module 300 is electrically connected to the first powermodule 502 and the second power module 504 through the direct currentside connecting conductive body 40. The direct current side connectingconductive body 40 extends an elongated through hole (elongated in thelongitudinal direction of the housing) extending at central portions ofthe first base 11 and second base between the upper and lower cooledchambers in the height direction of the housing.

The direct current side connecting conductive body 40 is aninterconnection line member of laminated structure in which a directcurrent positive pole side bus bar 45 of plate shape extending in thelongitudinal direction of the housing and a direct current negative poleside bus bar 44 of plate shape extending in the longitudinal directionof the housing are stacked through the insulating sheet 43 in thetransverse direction of the housing, the direct current positive poleside module terminal 44 and the positive pole side capacitor terminal 46are integrally formed with the direct current positive pole side bus bar45, and the direct current negative pole side module terminal 41 and thenegative pole side capacitor terminal 47 are integrally formed with thedirect current negative pole side bus bar 44. In this structure, a lowinductance is obtainable between the capacitor module 50 and the firstpower module 502 and second power module 504 so that the temporaryincrease in voltage during the stitching operation of the IGBT 21 isrestrained. Further, since the temporary increase in voltage isrestrained even when the switching speed is increased, the switchingspeed can be increased while the heat generation of the semiconductorduring the stitching operation is restrained.

The module terminal 42 of the direct current positive pole side extendsupward from the upper part of the direct current positive side bus bar45 at a position where the module terminal 33 at the direct currentpositive pole side projects upward from the resin case, and is fixed byscrew or the like to the direct current positive pole side moduleterminal 33 while facing to the direct current positive pole side moduleterminal 33 in the transverse direction of the housing to beelectrically connected to the direct current positive pole side moduleterminal 33. The direct current negative pole side module terminal 41extends upward from the upper part of the direct current negative poleside bus bar 44 at a position where the direct current negative poleside module terminal 26 projects upward from the resin case, and isfixed by screw or the like to the direct current negative pole sidemodule terminal 26 while facing to the direct current negative pole sidemodule terminal 26 in the transverse direction of the housing to beelectrically connected to the direct current negative pole side moduleterminal 26.

The capacitor terminal 46 at the positive pole side and the capacitorterminal 47 at the negative pole side extends downward from the lowerpart of the direct current positive pole side bus bar 45 and the directcurrent negative pole side bus bar 44 at a position where the capacitorterminal projects to arrange the capacitor terminals therebetween in thetransverse direction of the housing, and are fixed by screw or the liketo the capacitor terminals of the same pole while facing to them to beelectrically connected to the capacitor terminals of the same pole. Inthis interconnection line structure, the positive side and negative sideof the interconnection lines to the capacitor terminals from the directcurrent positive pole side bus bar 45 and the direct current negativepole side bus bar 44 face to each other to decrease the inductance ofthe interconnection lines so that the temporary increase in voltage isdecreased during the switching operation of the IGBT 21. Further, sincethe temporary increase in voltage is decreased even when the switchingspeed is increased, the switching speed is increased by the decrease ofinductance while keeping the increased voltage unchanged, so that theheat generation of the semiconductor is restrained during the switchingoperation.

In the above embodiment, the coolant water paths are arranged inparallel, and the terminals of the capacitor module 300 are connected tothe direct current terminals of the power modules 502 and 504 as thesemiconductor modules through holes between the coolant water paths toimprove the cooling efficiency and decrease the inductance.

The direct current terminal 80 is arranged at the end of the other sideof the housing in the longitudinal direction thereof. The direct currentterminal 80 includes the external terminal 82 of the direct currentpositive pole side, the external terminal 81 of the direct currentnegative pole side, the connecting terminal 86 of the direct currentpositive pole side, the connecting terminal 85 of the direct currentnegative pole side, the bus bar 84 at the direct current positive poleside for connecting the external terminal 82 of the direct currentpositive pole side and the connecting terminal 86 of the direct currentpositive pole side, and the bus bar 83 at the direct current negativepole side for connecting the external terminal 81 of the direct currentnegative pole side and the connecting terminal 85 of the direct currentnegative pole side.

The external terminal 82 of the direct current positive pole side andthe external terminal 81 of the direct current negative pole side areelectrically connected to external cables extending through a connectormounted in a through hole 17 formed on the side end surface of the otherside of the housing in the longitudinal direction thereof. The bus bar84 at the direct current positive pole side and the bus bar 83 at thedirect current negative pole side extend along the first power module502 and the second power module 504 to face to each other in thetransverse direction of the housing. The connecting terminal 86 of thedirect current positive pole side is electrically connected to themodule terminals 33 and 42 of the direct current positive pole side, andthe connecting terminal 85 of the direct current negative pole side iselectrically connected to the module terminals 26 and 41 of the directcurrent negative pole side.

The hole 18 formed on the upper surface of the upper case 10 is used toa connecting work between the external cables and the external terminals82 and 81 of the direct current positive and negative pole sides, and isclosed by the cover during a time period other than the connecting worktime.

The alternating current bus bars 60 for three phases are arranged ateach of internal ends of the housing in the transverse directionthereof. The alternating current bus bars 60 extend from the lowerchamber of the coolant water path to the upper chamber of the coolantwater path through the vertical (in the height direction of the housing)through hole formed at the ends of the first base 11 and second base 12in the transverse direction of the housing. The module terminal 61 atthe alternating side is formed on the end of the alternating bus bar 60in the upper chamber of the water path, and faces to the module terminal27 at the alternating current side in the transverse direction of thehousing to be fixed to the module terminal 27 at the alternating currentside by screw or the like to be electrically connected to the moduleterminal 27 at the alternating current side. The external connectingterminal 62 for the external cables connected to the rotary motors 130and 140 is formed at the other end side of the alternating bus bar 60 inthe lower chamber of the water path, and is supported by the terminalholder 63.

Incidentally, a reference number 14 denotes an attaching leg for fixingthe housing of the power converter 200 to the housing of thetransmission 105 or the housing of the transmission 105 and engine 104,which leg is made of a rigid body such as SUS to keep a strength.Further, it has a bent shape to achieve an elasticity for restraining avibration from the transmission and engine 104.

In the above described first and second embodiments, the coolant waterpath has the opening through which the heat radiating fin projects intothe water path to cool directly the heat radiating fin with the coolantwater as the coolant, so that the cooling efficiency is improved.

In the above described first and second embodiments, in addition todirect cooling of the heat radiating fin with the coolant water, theopening is closed by the metallic base plate to which the heat radiatingfin is adhered, so that the structure of the apparatus is simplified inaddition to the improvement of the cooling efficiency.

In the above described first and second embodiments, in addition todirect cooling of the heat radiating fin with the coolant water, thedirect current terminals of the power module containing therein theswitching semiconductor as the inverter and including the heat radiatingfin are aligned at one side of the power module, so that a connectingstructure to the capacitor module is simplified and the inductance isdecreased.

In the above described first and second embodiments, the coolant waterpaths are arranged in parallel, the openings of the coolant water pathsare arranged in parallel, the cooling fins projects in the openingsrespectively to be directly cooled, and the direct current terminals ofthe power module containing therein the switching semiconductor as theinverter and the heat radiating fin are aligned at the inside of thewater paths arranged in parallel, so that the connecting structure tothe capacitor module is simplified, and the inductance is decreased.Further, since the capacitor module is divided to a plurality of partsarranged in parallel, and the terminals of the capacitor module arearranged at the inside of the parallel arrangement, the inductance ofthe direct current circuit is decreased in addition to the improvementof the cooling efficiency and simplifying the structure as the whole.

In the above power module, the metallic base plate holding thesemiconductor element and the heat radiating fin is made of a materialincluding copper and the other metal to increase the hardness.Therefore, a deterioration in flatness caused by fixing the fin bybrazing is restrained to make the subsequent adhesion of the insulatingsubstrate including the plurality of the semiconductor chips easy.Further, the plurality of the insulating substrates are easily adheredto the common base plate, and a reliability thereof is kept after a longtime period of use.

It should be further understood by those skilled in the art thatalthough the foregoing description has been made on embodiments of theinvention, the invention is not limited thereto and various changes andmodifications may be made without departing from the spirit of theinvention and the scope of the appended claims.

1. A power converter to be connected to a rotary motor mounted on avehicle, comprising a metallic housing, a power module arranged in thehousing, a capacitor module arranged in the housing, and a cooling pathforming body forming a cooling path, wherein an opening is formed on thecooling path, the power module includes a metallic base plate, a heatradiating d fin fixed by brazing to a surface of the base plate, and aplurality of semiconductor chips held on another surface of the baseplate, the heat radiating fin of the power module projects from theopening into the cooling path, and the power module is fixed to thecooling path forming body so that the opening is closed by the baseplate of the power module.
 2. A power converter to be connected to arotary motor mounted on a vehicle, comprising a metallic housing, apower module arranged in the housing, a capacitor module arranged in thehousing, and a cooling path forming body forming a cooling path, whereinan opening is formed on the cooling path, the power module includes ametallic base plate, a heat radiating fin fixed by brazing to a surfaceof the base plate, and a plurality of semiconductor chips held onanother surface of the base plate, the power module is fixed to thecooling path forming body so that the heat radiating fin of the powermodule projects from the opening into the cooling path, an inlet pipefor taking in a coolant and an outlet pipe for discharging the coolantare fixed to the housing, an inlet portion of the cooling path is deeperthan a portion of the cooling path where the heat radiating finprojects, and an outlet portion of the cooling path is deeper than theportion of the cooling path where the heat radiating fin projects waterpaths for feeding a coolant water through the power converter mounted onan automobile are arranged in parallel, openings are formed on the waterpaths respectively, heat radiating fins project from the openings, andthe openings are closed by the base plate of the power module. Further,the base plate of the power module includes a metal in addition tocopper to increase a hardness of the base plate, so that a deteriorationof the flatness during fixing the fins with brazing is restrained. 3.The power converter to be connected to the rotary motor mounted on thevehicle, according to claim 1, wherein an insulating substrate is fixedby a solder layer to the another surface of the metallic base plate, andthe plurality of chips are fixed to the insulating substrate by thesolder layer.
 4. A power converter to be connected to a rotary motormounted on a vehicle, comprising a metallic housing, a plurality ofpower modules arranged in the housing, a capacitor module arranged inthe housing, and a water path forming body forming cooling paths,wherein the water path forming body includes the cooling paths arrangedin parallel, the cooling paths in parallel have respective openings,each of the power modules has a metallic base plate, a heat radiatingfin fixed to a surface of the base plate, and a plurality ofsemiconductor chips fixed to another surface of the base plate, one ofthe power modules is held by the water path forming body so that theheat radiating fin on the one of the power modules projects from theopening of one of the water paths arranged in parallel into the waterpath and the opening is closed by the base plate of the power module,the other one of the power modules is held by the water path formingbody so that the heat radiating fin on the other one of the powermodules projects from the opening of the other one of the water pathsarranged in parallel into the water path and the opening is closed bythe base plate of the power module, a metallic holding body of waveshape is fixed to the housing, the capacitor module is fixed to theholding body of wave shape, the water path forming body is fixed to thehousing, and the water path forming body is cooled by a coolant waterflowing in the water paths so that the housing as well as the powermodule are cooled, the metallic holding body of wave shape is cooled,and the capacitor module is cooled.
 5. A power converter to be connectedto a rotary motor mounted on a vehicle, comprising a metallic housing, aplurality of power modules arranged in the housing, a capacitor modulearranged in the housing, and a water path forming body forming coolantwater paths, the water path forming body includes the coolant waterpaths arranged in parallel, the coolant water paths in parallel haverespective openings, each of the power modules has a metallic baseplate, a heat radiating fin fixed on a surface of the base plate, and aplurality of semiconductor chips fixed to another surface of the baseplate, one of the power modules is held by the water path forming bodyso that the heat radiating fin on the one of the power modules projectsfrom the opening of one of the water paths arranged in parallel into thewater path and the opening is closed by the base plate of the powermodule, the other one of the power modules is held by the water pathforming body so that the heat radiating fin on the other one of thepower modules projects from the opening of the other one of the waterpaths arranged in parallel into the water path and the opening is closedby the base plate of the power module, an inlet pipe for taking in acoolant water and an outlet pipe for discharging the coolant water arefixed to the housing, an inlet portion of the coolant water pathcommunicating with the inlet pipe of the coolant water path is deeperthan a portion of the coolant water path where the heat radiating finprojects, an outlet portion of the coolant water path communicating withthe outlet pipe of the coolant water path is deeper than the portion ofthe coolant water path where the heat radiating fin projects, and a foldback portion of the coolant water path connecting the coolant waterpaths arranged in parallel to each other is deeper than the portion ofthe coolant water path where the heat radiating fin projects.
 6. Thepower converter to be connected to the rotary motor mounted on thevehicle, according to claim 4 or 5, wherein an insulating substrate isfixed to the another surface of the base plate of each of the powermodules, the plurality of chips are fixed to the insulating substrate,in each of the power modules arranged in parallel, connecting terminalsto the capacitor are arranged at an inside of the parallel arrangement,and alternating current terminals to be connected to the rotary motorare arranged at an outside of the parallel arrangement.
 7. The powerconverter to be connected to the rotary motor mounted on the vehicle,according to claim 4 or 5, wherein an insulating substrate is fixed by asolder layer to the another surface of the base plate of each of thepower modules, the plurality of chips are fixed by the solder layer tothe insulating substrate, in each of the power modules arranged inparallel, connecting terminals to the capacitor are arranged at aninside of the parallel arrangement, and alternating current terminals tobe connected to the rotary motor are arranged at an outside of theparallel arrangement.
 8. The power converter to be connected to therotary motor mounted on the vehicle, according to any one of claims 1,wherein the base plate of the power module is an alloy including copperas main component and another metal, and a hardness of the copper alloyon the another surface is not less than HV50 in a condition where theheat radiating fin is fixed the base plate.
 9. The power converter to beconnected to the rotary motor mounted on the vehicle, according to claim8, wherein the heat radiating fin is fixed by brazing to the surface ofthe base plate, a thickness of the base plate is 2-4 mm, and its thermalconductivity is not less than 200 W/mK.
 10. The power converter to beconnected to the rotary motor mounted on the vehicle, according to claim8, wherein the base plate includes a thin coating of nickel with athickness not less than 3 μm and not more than 9 μm.
 11. A powerconverter to be connected to a rotary motor mounted on a vehicle,comprising a metallic housing, a power module and a capacitor modulearranged in the housing, and a cooling path forming body forming acooling path, an opening is formed on the cooling path, the power modulehas a metallic base plate, a heat radiating fin fixed by brazing to asurface of the base plate, and a plurality of semiconductor chips heldon another surface of the base plate, the power module is fixed to asurface of the cooling path forming body so that the heat radiating finof the power module projects from the opening into the cooling path andthe opening is closed by the base plate of the power module, and thecapacitor module is fixed onto another surface of the cooling water pathforming body.
 12. A power converter to be connected to a rotary motormounted on a vehicle, comprising a metallic housing, a power module anda capacitor module arranged in the housing, and a cooling path formingbody forming a cooling path, an opening is formed on the cooling path,the power module has a metallic base plate, a heat radiating fin fixedby brazing to a surface of the base plate, and a plurality ofsemiconductor chips held on another surface of the base plate, the powermodule is fixed to a surface of the cooling path forming body so thatthe heat radiating fin of the power module projects from the openinginto the cooling path, and the capacitor module is fixed onto anothersurface of the cooling water path forming body, an inlet pipe for takingin a coolant and an outlet pipe for discharging the coolant are fixed tothe housing, an inlet portion of the cooling path communicating with theinlet pipe is deeper than a portion of the cooling path where the heatradiating fin projects, an outlet portion of the cooling pathcommunicating with the outlet pipe is deeper than the portion of thecooling path where the heat radiating fin projects.
 13. The powerconverter to be connected to the rotary motor mounted on the vehicle,according to claim 11, wherein an insulating substrate is fixed by asolder layer to the another surface of the metallic base plate, and theplurality of chips are fixed by the solder layer to the insulatingsubstrate.
 14. A power converter to be connected to a rotary motormounted on a vehicle, comprising a metallic housing, a plurality ofpower modules and a capacitor module arranged in the housing, and awater path forming body forming coolant water paths, wherein the waterpath forming body is fixed to the housing and has the coolant waterpaths arranged in parallel, openings are formed respectively on thecoolant water paths in parallel, each of the power modules has ametallic base plate, a heat radiating fin fixed to a surface of the baseplate, and a plurality of semiconductor chips fixed to another surfaceof the base plate, one of the power modules is fixed to a surface of thewater path forming body so that the heat radiating fin on the one of thepower modules projects from the opening of one of the coolant waterpaths in parallel into the water path and the opening is closed by thebase plate of the power module, the other one of the power modules isfixed to the surface of the water path forming body so that the heatradiating fin on the other one of the power modules projects from theopening of the other one of the coolant water paths in parallel into thewater path and the opening is closed by the base plate of the powermodule, and the capacitor module is fixed to another surface of thewater path forming body.
 15. A power converter to be connected to arotary motor mounted on a vehicle, comprising a metallic housing, aplurality of power modules and a capacitor module arranged in thehousing, and a water path forming body forming coolant water paths,wherein the water path forming has the coolant water paths arranged inparallel, openings are formed respectively on the coolant water paths inparallel, each of the power modules has a metallic base plate, a heatradiating fin fixed to a surface of the base plate, and a plurality ofsemiconductor chips fixed to another surface of the base plate, one ofthe power modules is fixed to a surface of the water path forming bodyso that the heat radiating fin on the one of the power modules projectsfrom the opening of one of the coolant water paths in parallel into thewater path and the opening is closed by the base plate of the powermodule, the other one of the power modules is fixed to the surface ofthe water path forming body so that the heat radiating fin on the otherone of the power modules projects from the opening of the other one ofthe coolant water paths in parallel into the water path and the openingis closed by the base plate of the power module, the capacitor module isfixed to another surface of the water path forming body, an inlet pipefor taking in a coolant water and an outlet pipe for discharging thecoolant water are fixed to the housing, an inlet portion of the coolantwater path communicating with the inlet pipe of the coolant water pathis deeper than a portion of the coolant water path where the heatradiating fin projects, an outlet portion of the coolant water pathcommunicating with the outlet pipe of the coolant water path is deeperthan the portion of the coolant water path where the heat radiating finprojects, and a fold back portion of the coolant water path connectingthe coolant water paths arranged in parallel to each other is deeperthan the portion of the coolant water path where the heat radiating finprojects.
 16. The power converter to be connected to the rotary motormounted on the vehicle, according to claim 14, wherein an insulatingsubstrate is fixed to the another surface of the base plate of each ofthe power modules, the plurality of chips are fixed to the insulatingsubstrate, in each of the power modules arranged in parallel, connectingterminals to the capacitor are arranged at an inside of the parallelarrangement, and alternating current terminals to be connected to therotary motor are arranged at an outside of the parallel arrangement. 17.The power converter to be connected to the rotary motor mounted on thevehicle, according to claim 14, wherein the heat radiating fin is fixedby brazing to a surface of the base plate of each of the power modules,an insulating substrate is fixed to the another surface of the baseplate of each of the power modules, the plurality of chips are fixed tothe insulating substrate, in each of the power modules arranged inparallel, connecting terminals to the capacitor are arranged at aninside of the parallel arrangement, and alternating current terminals tobe connected to the rotary motor are arranged at an outside of theparallel arrangement.
 18. The power converter to be connected to therotary motor mounted on the vehicle, according to claim 11, wherein thebase plate of the power module is an alloy including copper as maincomponent and another metal, and a hardness of the copper alloy on theanother surface is not less than HV50 in a condition where the heatradiating fin is fixed the base plate.
 19. The power converter to beconnected to the rotary motor mounted on the vehicle, according to claim18, wherein the heat radiating fin is fixed by brazing to the surface ofthe base plate, a thickness of the base plate is 2-4 mm, and its thermalconductivity is not less than 200 W/mK.
 20. The power converter to beconnected to the rotary motor mounted on the vehicle, according to claim18, wherein the base plate includes a thin coating of nickel with athickness not less than 3 μm and not more than 9 μm.